Golf club heads and methods to manufacture golf club heads

ABSTRACT

Embodiments of golf club heads and methods to manufacture golf club heads are generally described herein. In one example, a method of manufacturing a golf club head may include forming a body portion having an interior cavity portion and a plurality of ports, forming a face portion, attaching the face portion to the body portion to close the interior cavity, injecting a polymer material into the interior cavity portion through a port in the body portion, and closing the ports with a plurality of mass portions. Other examples and embodiments may be described and claimed.

COPYRIGHT AUTHORIZATION

The present disclosure may be subject to copyright protection. Thecopyright owner has no objection to the facsimile reproduction by anyoneof the present disclosure and its related documents, as they appear inthe Patent and Trademark Office patent files or records, but otherwisereserves all applicable copyrights.

CROSS REFERENCE

This application is a continuation of application Ser. No. 17/038,195filed Sep. 30, 2020, which is a continuation of application Ser. No.16/365,343, filed Mar. 26, 2019, now U.S. Pat. No. 10,821,340, which isa continuation of application Ser. No. 15/841,022, filed Dec. 13, 2017,now U.S. Pat. No. 10,265,590, which is a continuation of applicationSer. No. 15/701,131, filed Sep. 11, 2017, now abandoned, which is acontinuation-in-part of application Ser. No. 15/685,986, filed Aug. 24,2017, now U.S. Pat. No. 10,279,233, which is a continuation ofapplication Ser. No. 15/628,251, filed Jun. 20, 2017, now abandoned,which is a continuation of application Ser. No. 15/209,364, filed onJul. 13, 2016, now U.S. Pat. No. 10,293,229, which is a continuation ofInternational Application No. PCT/US15/16666, filed Feb. 19, 2015, whichclaims the benefit of U.S. Provisional Application No. 61/942,515, filedFeb. 20, 2014, U.S. Provisional Application No. 61/945,560, filed Feb.27, 2014, U.S. Provisional Application No. 61/948,839, filed Mar. 6,2014, U.S. Provisional Application No. 61/952,470, filed Mar. 13, 2014,U.S. Provisional Application No. 61/992,555, filed May 13, 2014, U.S.Provisional Application No. 62/010,836, filed Jun. 11, 2014, U.S.Provisional Application No. 62/011,859, filed Jun. 13, 2014, and U.S.Provisional Application No. 62/032,770, filed Aug. 4, 2014. U.S.application Ser. No. 15/209,364, filed on Jul. 13, 2016, now U.S. Pat.No. 10,293,229, is also a continuation of application Ser. No.14/618,501, filed Feb. 10, 2015, now U.S. Pat. No. 9,427,634, which is acontinuation of application Ser. No. 14/589,277, filed Jan. 5, 2015, nowU.S. Pat. No. 9,421,437, which is a continuation of application Ser. No.14/513,073, filed Oct. 13, 2014, now U.S. Pat. No. 8,961,336, which is acontinuation of application Ser. No. 14/498,603, filed Sep. 26, 2014,now U.S. Pat. No. 9,199,143, which claims the benefits of U.S.Provisional Application No. 62/041,538, filed Aug. 25, 2014.

The disclosures of the above-referenced applications are incorporated byreference herein in their entirety.

FIELD

The present disclosure generally relates to golf equipment, and moreparticularly, to golf club heads and methods to manufacturing golf clubheads.

BACKGROUND

Various materials (e.g., steel-based materials, titanium-basedmaterials, tungsten-based materials, etc.) may be used to manufacturegolf club heads. By using multiple materials to manufacture golf clubheads, the position of the center of gravity (CG) and/or the moment ofinertia (MOI) of the golf club heads may be optimized to produce certaintrajectories and spin rates of a golf ball.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a front view of a golf club head according to anembodiment of the apparatus, methods, and articles of manufacturedescribed herein.

FIG. 2 depicts a rear view of the example golf club head of FIG. 1.

FIG. 3 depicts a top view of the example golf club head of FIG. 1.

FIG. 4 depicts a bottom view of the example golf club head of FIG. 1.

FIG. 5 depicts a left view of the example golf club head of FIG. 1.

FIG. 6 depicts a right view of the example golf club head of FIG. 1.

FIG. 7 depicts a cross-sectional view of the example golf club head ofFIG. 1 along line 7-7.

FIG. 8 depicts a cross-sectional view of the example golf club head ofFIG. 1 along line 8-8.

FIG. 9 depicts a cross-sectional view of the example golf club head ofFIG. 1 along line 9-9.

FIG. 10 depicts another rear view of the example golf club head of FIG.1.

FIG. 11 depicts a top view of a weight portion associated with theexample golf club head of FIG. 1.

FIG. 12 depicts a side view of a weight portion associated with theexample golf club head of FIG. 1.

FIG. 13 depicts a side view of another weight portion associated withthe example golf club head of FIG. 1.

FIG. 14 depicts a rear view of a body portion of the example golf clubhead of FIG. 1.

FIG. 15 depicts a cross-sectional view of a face portion of the examplegolf club head of FIG. 1.

FIG. 16 depicts a cross-sectional view of another face portion of theexample golf club head of FIG. 1.

FIG. 17 depicts one manner in which the example golf club head describedherein may be manufactured.

FIG. 18 depicts another cross-sectional view of the example golf clubhead of FIG. 4 along line 18-18.

FIG. 19 depicts one manner in which an example golf club describedherein may be manufactured.

For simplicity and clarity of illustration, the drawing figuresillustrate the general manner of construction, and descriptions anddetails of well-known features and techniques may be omitted to avoidunnecessarily obscuring the present disclosure. Additionally, elementsin the drawing figures may not be depicted to scale. For example, thedimensions of some of the elements in the figures may be exaggeratedrelative to other elements to help improve understanding of embodimentsof the present disclosure.

DESCRIPTION

In general, golf club heads and methods to manufacture golf club headsare described herein. The apparatus, methods, and articles ofmanufacture described herein are not limited in this regard.

In the example of FIGS. 1-14, a golf club head 100 may include a bodyportion 110 (FIG. 14), and two or more weight portions, generally shownas a first set of weight portions 120 (e.g., shown as weight portions121, 122, 123, and 124) and a second set of weight portions 130 (e.g.,shown as weight portions 131, 132, 133, 134, 135, 136, and 137). Thebody portion 110 may include a toe portion 140, a heel portion 150, afront portion 160, a back portion 170, a top portion 180, and a soleportion 190. The body portion 110 may be made of a first material (forexample, as shown in FIG. 19, the body portion 110 may be formed atblock 1910 of a process 1900 for manufacturing a golf club) whereas thefirst and second sets of weight portions 120 and 130, respectively, maybe made of a second material. The first and second materials may besimilar or different materials. For example, the body portion 110 may bepartially or entirely made of a steel-based material (e.g., 17-4 PHstainless steel, Nitronic® 50 stainless steel, maraging steel or othertypes of stainless steel), a titanium-based material, an aluminum-basedmaterial (e.g., a high-strength aluminum alloy or a composite aluminumalloy coated with a high-strength alloy), any combination thereof,and/or other suitable types of materials. The first and second sets ofweight portions 120 and 130, respectively, may be partially or entirelymade of a high-density material such as a tungsten-based material orother suitable types of materials. Alternatively, the body portion 110and/or the first and second sets of weight portions 120 and 130,respectively, may be partially or entirely made of a non-metal material(e.g., composite, plastic, etc.). The apparatus, methods, and articlesof manufacture are not limited in this regard.

The golf club head 100 may be an iron-type golf club head (e.g., a1-iron, a 2-iron, a 3-iron, a 4-iron, a 5-iron, a 6-iron, a 7-iron, an8-iron, a 9-iron, etc.) or a wedge-type golf club head (e.g., a pitchingwedge, a lob wedge, a sand wedge, an n-degree wedge such as 44degrees)(°, 48°, 52°, 56°, 60°, etc.). Although FIGS. 1-10 may depict aparticular type of club head, the apparatus, methods, and articles ofmanufacture described herein may be applicable to other types of clubheads (e.g., a driver-type club head, a fairway wood-type club head, ahybrid-type club head, a putter-type club head, etc.). The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

The toe portion 140 and the heel portion 150 may be on opposite ends ofthe body portion 110. The heel portion 150 may include a hosel portion155 configured to receive a shaft (not shown. For example, as shown inFIG. 19, a shaft may be attached to the body portion at block 1960 ofthe process 1900 for manufacturing a golf club) with a grip (not shown)on one end and the golf club head 100 on the opposite end of the shaftto form a golf club.

The front portion 160 may include a face portion 162 (e.g., a strikeface). The face portion 162 may include a front surface 164 and a backsurface 166. The front surface 164 may include one or more grooves 168extending between the toe portion 140 and the heel portion 150. Whilethe figures may depict a particular number of grooves, the apparatus,methods, and articles of manufacture described herein may include moreor less grooves. The face portion 162 may be used to impact a golf ball(not shown). The face portion 162 may be an integral portion of the bodyportion 110. Alternatively, the face portion 162 may be a separate piece(for example, as shown in FIG. 19, the face portion 162 may be formed atblock 1920 of the process 1900 for manufacturing a golf club), or aninsert coupled to the body portion 110 (for example, as shown in FIG.19, the face portion 162 may be attached to the body portion 110 atblock 1930 of the process 1900 for manufacturing a golf club) viavarious manufacturing methods and/or processes (e.g., a bonding process,a welding process, a brazing process, a mechanical locking method, anycombination thereof, or other suitable types of manufacturing methodsand/or processes). The face portion 162 may be associated with a loftplane that defines the loft angle of the golf club head 100. The loftangle may vary based on the type of golf club (e.g., a long iron, amiddle iron, a short iron, a wedge, etc.). In one example, the loftangle may be between five degrees and seventy-five degrees. In anotherexample, the loft angle may be between twenty degrees and sixty degrees.The apparatus, methods, and articles of manufacture described herein arenot limited in this regard.

As illustrated in FIG. 14, the back portion 170 may include a back wallportion 1410 with one or more exterior weight ports along a periphery ofthe back portion 170, generally shown as a first set of exterior weightports 1420 (e.g., shown as weight ports 1421, 1422, 1423, and 1424) anda second set of exterior weight ports 1430 (e.g., shown as weight ports1431, 1432, 1433, 1434, 1435, 1436, and 1437). Each exterior weight portmay be associated with a port diameter. In one example, the portdiameter may be about 0.25 inch (6.35 millimeters). Any two adjacentexterior weight ports of the first set of exterior weight ports 1420 maybe separated by less than the port diameter. In a similar manner, anytwo adjacent exterior weight ports of the second set of exterior weightports 1430 may be separated by less than the port diameter. The firstand second exterior weight ports 1420 and 1430 may be exterior weightports configured to receive one or more weight portions. In particular,each weight portion of the first set 120 (e.g., shown as weight portions121, 122, 123, and 124) may be disposed in a weight port located at orproximate to the toe portion 140 and/or the top portion 180 on the backportion 170. For example, the weight portion 121 may be partially orentirely disposed in the weight port 1421. In another example, theweight portion 122 may be disposed in a weight port 1422 located in atransition region between the top portion 180 and the toe portion 140(e.g., a top-and-toe transition region). Each weight portion of thesecond set 130 (e.g., shown as weight portions 131, 132, 133, 134, 135,136, and 137) may be disposed in a weight port located at or proximateto the toe portion 140 and/or the sole portion 190 on the back portion170. For example, the weight portion 135 may be partially or entirelydisposed in the weight port 1435. In another example, the weight portion136 may be disposed in a weight port 1436 located in a transition regionbetween the sole portion 190 and the toe portion 140 (e.g., asole-and-toe transition region). As described in detail below, the firstand second sets of weight portions 120 and 130, respectively, may becoupled to the back portion 170 of the body portion 110 with variousmanufacturing methods and/or processes (e.g., a bonding process, awelding process, a brazing process, a mechanical locking method, anycombination thereof, or other suitable manufacturing methods and/orprocesses).

Alternatively, the golf club head 100 may not include (i) the first setof weight portions 120, (ii) the second set of weight portions 130, or(iii) both the first and second sets of weight portions 120 and 130. Inparticular, the back portion 170 of the body portion 110 may not includeweight ports at or proximate to the top portion 180 and/or the soleportion 190. For example, the mass of the first set of weight portions120 (e.g., 3 grams) and/or the mass of the second set of weight portions130 (e.g., 16.8 grams) may be integral part(s) of the body portion 110instead of separate weight portion(s). The apparatus, methods, andarticles of manufacture described herein are not limited in this regard.

The first and second sets of weight portions 120 and 130, respectively,may have similar or different physical properties (e.g., color, shape,size, density, mass, volume, etc.). As a result, the first and secondsets of weight portions 120 and 130, respectively, may contribute to theornamental design of the golf club head 100. In the illustrated exampleas shown in FIG. 11, each of the weight portions of the first and secondsets 120 and 130, respectively, may have a cylindrical shape (e.g., acircular cross section). Alternatively, each of the weight portions ofthe first set 120 may have a first shape (e.g., a cylindrical shape)whereas each of the weight portions of the second set 130 may have asecond shape (e.g., a cubical shape). In another example, the first setof weight portions 120 may include two or more weight portions withdifferent shapes (e.g., the weight portion 121 may be a first shapewhereas the weight portion 122 may be a second shape different from thefirst shape). Likewise, the second set of weight portions 130 may alsoinclude two or more weight portions with different shapes (e.g., theweight portion 131 may be a first shape whereas the weight portion 132may be a second shape different from the first shape). Although theabove examples may describe weight portions having a particular shape,the apparatus, methods, and articles of manufacture described herein mayinclude weight portions of other suitable shapes (e.g., a portion of ora whole sphere, cube, cone, cylinder, pyramid, cuboidal, prism, frustum,or other suitable geometric shape). While the above examples and figuresmay depict multiple weight portions as a set of weight portions, eachset of the first and second sets of weight portions 120 and 130,respectively, may be a single piece of weight portion. In one example,the first set of weight portions 120 may be a single piece of weightportion instead of a series of four separate weight portions. In anotherexample, the second set of weight portions 130 may be a single piece ofweight portion instead of a series of seven separate weight portions.The apparatus, methods, and articles of manufacture described herein arenot limited in this regard.

Referring to FIGS. 12 and 13, for example, the first and second sets ofweight portions 120 and 130, respectively, may include threads,generally shown as 1210 and 1310, respectively, to engage withcorrespondingly configured threads in the weight ports to secure in theweight ports of the back portion 170 (generally shown as 1420 and 1430in FIG. 14). For example, each weight portion of the first and secondsets of weight portions 120 and 130, respectively, may be a screw. Thefirst and second sets of weight portions 120 and 130, respectively, maynot be readily removable from the body portion 110 with or without atool. Alternatively, the first and second sets of weight portions 120and 130, respectively, may be readily removable (e.g., with a tool) sothat a relatively heavier or lighter weight portion may replace one ormore of the weight portions of the first and second sets 120 and 130,respectively. In another example, the first and second sets of weightportions 120 and 130, respectively, may be secured in the weight portsof the back portion 170 with epoxy or adhesive so that the first andsecond sets of weight portions 120 and 130, respectively, may not bereadily removable. In yet another example, the first and second sets ofweight portions 120 and 130, respectively, may be secured in the weightports of the back portion 170 with both epoxy and threads so that thefirst and second sets of weight portions 120 and 130, respectively, maynot be readily removable. The apparatus, methods, and articles ofmanufacture described herein are not limited in this regard.

As mentioned above, the first and second sets of weight portions 120 and130, respectively, may be similar in some physical properties butdifferent in other physical properties. As illustrated in FIGS. 11-13,for example, each of the weight portions of the first and second sets120 and 130, respectively, may have a diameter 1110 of about 0.25 inch(6.35 millimeters) but the first and second sets of weight portions 120and 130, respectively, may be different in height. In particular, eachof the weight portions of the first set 120 may be associated with afirst height 1220 (FIG. 12), and each of the weight portion of thesecond set 130 may be associated with a second height 1320 (FIG. 13).The first height 1220 may be relatively shorter than the second height1320. In one example, the first height 1220 may be about 0.125 inch(3.175 millimeters) whereas the second height 1320 may be about 0.3 inch(7.62 millimeters). In another example, the first height 1220 may beabout 0.16 inch (4.064 millimeters) whereas the second height 1320 maybe about 0.4 inch (10.16 millimeters). Alternatively, the first height1220 may be equal to or greater than the second height 1320. Theapparatus, methods, and articles of manufacture described herein are notlimited in this regard.

To provide optimal perimeter weighting for the golf club head 100, thefirst set of weight portions 120 (e.g., weight portions 121, 122, 123,and 124) may be configured to counter-balance the weight of the hosel155. The second set of weight portions 130 (e.g., weight portions 131,132, 133, 134, 135, 136, and 137) may be configured to place the centerof gravity of the golf club head 100 at an optimal location. Turning toFIGS. 7-9, for example, the first and second sets of weight portions 120and 130, respectively, may be located away from the back surface 166 ofthe face portion 162 (e.g., not directly coupled to each other). Thatis, the first and second sets of weight portions 120 and 130,respectively, and the back surface 166 may be partially or entirelyseparated by an interior cavity 700 of the body portion 110. As shown inFIG. 14, for example, each exterior weight port of the first and secondsets of exterior weight ports 1420 and 1430 may include an opening(e.g., generally shown as 720 and 730) and a port wall (e.g., generallyshown as 725 and 735). The port walls 725 and 735 may be integralportions of the back wall portion 1410 (e.g., a section of the back wallportion 1410). Each of the openings 720 and 730 may be configured toreceive a weight portion such as weight portions 121 and 135,respectively (for example, as shown in FIG. 19, at block 1950 of theprocess 1900 for manufacturing a golf club, a mass portion, i.e., weightportion, may be inserted into the weight port to close the port). Theopening 720 may be located at one end of the weight port 1421, and theport wall 725 may be located or proximate to at an opposite end of theweight port 1421. In a similar manner, the opening 730 may be located atone end of the weight port 1435, and the port wall 735 may be located ator proximate to an opposite end of the weight port 1435. The port walls725 and 735 may be separated from the face portion 162 (e.g., separatedby the interior cavity 700). As a result, the center of gravity (CG) ofthe golf club head 100 may be relatively farther back away from the faceportion 162 and relatively lower towards a ground plane (e.g., one shownas 1010 in FIG. 10) with the second set of weight portions 130 beingaway from the back surface 166 than if the second set of weight portions130 were directly coupled to the back surface 166. The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

While the figures may depict weight ports with a particularcross-section shape, the apparatus, methods, and articles of manufacturedescribed herein may include weight ports with other suitablecross-section shapes. In one example, the weight ports of the firstand/or second sets of weight ports 1420 and 1430 may have U-likecross-section shape. In another example, the weight ports of the firstand/or second set of weight ports 1420 and 1430 may have V-likecross-section shape. One or more of the weight ports associated with thefirst set of weight portions 120 may have a different cross-sectionshape than one or more weight ports associated with the second set ofweight portions 130. For example, the weight port 1421 may have a U-likecross-section shape whereas the weight port 1435 may have a V-likecross-section shape. Further, two or more weight ports associated withthe first set of weight portions 120 may have different cross-sectionshapes. In a similar manner, two or more weight ports associated withthe second set of weight portions 130 may have different cross-sectionshapes. The apparatus, methods, and articles of manufacture describedherein are not limited in this regard.

Referring back to FIG. 10, for example, the golf club head 100 may beassociated with a ground plane 1010, a horizontal midplane 1020, and atop plane 1030. In particular, the ground plane 1010 may be a tangentialplane to the sole portion 190 of the golf club head 100 when the golfclub head 100 is at an address position (e.g., the golf club head 100 isaligned to strike a golf ball). A top plane 1030 may be a tangentialplane to the top portion of the 180 of the golf club head 100 when thegolf club head 100 is at the address position. The ground and top planes1010 and 1030, respectively, may be substantially parallel to eachother. The horizontal midplane 1020 may be vertically halfway betweenthe ground and top planes 1010 and 1030, respectively.

The first and second sets of weight portions 120 and 130, respectively,may be similar in mass (e.g., all of the weight portions of the firstand second sets 120 and 130, respectively, weigh about the same).Alternatively, the first and second sets of weight portions 120 and 130,respectively, may be different in mass individually or as an entire set.In particular, each of the weight portions of the first set 120 (e.g.,shown as 121, 122, 123, and 124) may have relatively less mass than anyof the weight portions of the second set 130 (e.g., shown as 131, 132,133, 134, 135, 136, and 137). For example, the second set of weightportions 130 may account for more than 50% of the total mass fromexterior weight portions of the golf club head 100. As a result, thegolf club head 100 may be configured to have at least 50% of the totalmass from exterior weight portions disposed below the horizontalmidplane 1020. The apparatus, methods, and articles of manufacturedescribed herein are not limited in this regard.

In one example, the golf club head 100 may have a mass in the range ofabout 220 grams to about 330 grams based on the type of golf club (e.g.,a 4-iron versus a lob wedge). The body portion 110 may have a mass inthe range of about 200 grams to about 310 grams with the first andsecond sets of weight portions 120 and 130, respectively, having a massof about 20 grams (e.g., a total mass from exterior weight portions).Each of the weight portions of the first set 120 may have a mass ofabout one gram (1.0 g) whereas each of the weight portions of the secondset 130 may have a mass of about 2.4 grams. The sum of the mass of thefirst set of weight portions 120 may be about 3 grams whereas the sum ofthe mass of the first set of weight portions 130 may be about 16.8grams. The total mass of the second set of weight portions 130 may weighmore than five times as much as the total mass of the first set ofweight portions 120 (e.g., a total mass of the second set of weightportions 130 of about 16.8 grams versus a total mass of the first set ofweight portions 120 of about 3 grams). The golf club head 100 may have atotal mass of 19.8 grams from the first and second sets of weightportions 120 and 130, respectively (e.g., sum of 3 grams from the firstset of weight portions 120 and 16.8 grams from the second set of weightportions 130). Accordingly, the first set of weight portions 120 mayaccount for about 15% of the total mass from exterior weight portions ofthe golf club head 100 whereas the second set of weight portions 130 maybe account for about 85% of the total mass from exterior weight portionsof the golf club head 100. The apparatus, methods, and articles ofmanufacture described herein are not limited in this regard.

By coupling the first and second sets of weight portions 120 and 130,respectively, to the body portion 110 (e.g., securing the first andsecond sets of weight portions 120 and 130 in the weight ports on theback portion 170), the location of the center of gravity (CG) and themoment of inertia (MOI) of the golf club head 100 may be optimized. Inparticular, the first and second sets of weight portions 120 and 130,respectively, may lower the location of the CG towards the sole portion190 and further back away from the face portion 162. Further, the MOImay be higher as measured about a vertical axis extending through the CG(e.g., perpendicular to the ground plane 1010). The MOI may also behigher as measured about a horizontal axis extending through the CG(e.g., extending towards the toe and heel portions 150 and 160,respectively, of the golf club head 100). As a result, the club head 100may provide a relatively higher launch angle and a relatively lower spinrate than a golf club head without the first and second sets of weightportions 120 and 130, respectively. The apparatus, methods, and articlesof manufacture described herein are not limited in this regard.

Alternatively, two or more weight portions in the same set may bedifferent in mass. In one example, the weight portion 121 of the firstset 120 may have a relatively lower mass than the weight portion 122 ofthe first set 120. In another example, the weight portion 131 of thesecond set 130 may have a relatively lower mass than the weight portion135 of the second set 130. With relatively greater mass at thetop-and-toe transition region and/or the sole-and-toe transition region,more weight may be distributed away from the center of gravity (CG) ofthe golf club head 100 to increase the moment of inertia (MOI) about thevertical axis through the CG.

Although the figures may depict the weight portions as separate andindividual parts, each set of the first and second sets of weightportions 120 and 130, respectively, may be a single piece of weightportion. In one example, all of the weight portions of the first set 120(e.g., shown as 121, 122, 123, and 124) may be combined into a singlepiece of weight portion (e.g., a first weight portion). In a similarmanner, all of the weight portions of the second set 130 (e.g., 131,132, 133, 134, 135, 136, and 137) may be combined into a single piece ofweight portion as well (e.g., a second weight portion). In this example,the golf club head 100 may have only two weight portions. While thefigures may depict a particular number of weight portions, theapparatus, methods, and articles of manufacture described herein mayinclude more or less number of weight portions. In one example, thefirst set of weight portions 120 may include two separate weightportions instead of three separate weight portions as shown in thefigures. In another example, the second set of weight portions 130 mayinclude five separate weight portions instead of seven separate weightportions a shown in the figures. Alternatively as mentioned above, theapparatus, methods, and articles of manufacture described herein may notinclude any separate weight portions (e.g., the body portion 110 may bemanufactured to include the mass of the separate weight portions asintegral part(s) of the body portion 110). The apparatus, methods, andarticles of manufacture described herein are not limited in this regard.

Referring back to FIGS. 7-9, for example, the body portion 110 may be ahollow body including the interior cavity 700 extending between thefront portion 160 and the back portion 170. Further, the interior cavity700 may extend between the top portion 180 and the sole portion 190. Theinterior cavity 700 may be associated with a cavity height 750 (H_(C)),and the body portion 110 may be associated with a body height 850(H_(B)). While the cavity height 750 and the body height 850 may varybetween the toe and heel portions 140 and 150, the cavity height 750 maybe at least 50% of a body height 850 (H_(C)>0.5*H_(B)). For example, thecavity height 750 may vary between 70-85% of the body height 850. Withthe cavity height 750 of the interior cavity 700 being greater than 50%of the body height 850, the golf club head 100 may produce relativelymore consistent feel, sound, and/or result when the golf club head 100strikes a golf ball via the face portion 162 than a golf club head witha cavity height of less than 50% of the body height. The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

In one example, the interior cavity 700 may be unfilled (i.e., emptyspace). The body portion 110 with the interior cavity 700 may weightabout 100 grams less than the body portion 110 without the interiorcavity 700. Alternatively, the interior cavity 700 may be partially orentirely filled with an elastic polymer or elastomer material (e.g., aviscoelastic urethane polymer material such as Sorbothane® materialmanufactured by Sorbothane, Inc., Kent, Ohio, a thermoplastic elastomermaterial (TPE), or a thermoplastic polyurethane material (TPU)), and/orother suitable types of materials to absorb shock, isolate vibration,and/or dampen noise. For example, at least 50% of the interior cavity700 may be filled with a TPE material to absorb shock, isolatevibration, and/or dampen noise when the golf club head 100 strikes agolf ball via the face portion 162. The apparatus, methods, and articlesof manufacture described herein are not limited in this regard.

Turning to FIG. 15, for example, the face portion 162 may include afirst thickness 1510 (T₁), and a second thickness 1520 (T₂). The firstthickness 1510 may be a thickness of a section of the face portion 162adjacent to a groove 168 whereas the second thickness 1520 may be athickness of a section of the face portion 162 below the groove 168. Forexample, the first thickness 1510 may be a maximum distance between thefront surface 164 and the back surface 166. The second thickness 1520may be based on the groove 168. In particular, the groove 168 may have agroove depth 1525 (D_(groove)). The second thickness 1520 may be amaximum distance between the bottom of the groove 168 and the backsurface 166. The sum of the second thickness 1520 and the groove depth1525 may be substantially equal to the first thickness 1510 (e.g.,T₂+D_(groove)=T₁). Accordingly, the second thickness 1520 may be lessthan the first thickness 1510 (e.g., T₂<T₁).

To lower and/or move the CG of the golf club head 100 further back,weight from the front portion 160 of the golf club head 100 may beremoved by using a relatively thinner face portion 162. For example, thefirst thickness 1510 may be about 0.075 inch (1.905 millimeters) (e.g.,T₁=0.075 inch). With the support of the back wall portion 1410 to formthe interior cavity 700 and filling at least a portion of the interiorcavity 700 with an elastic polymer material, the face portion 162 may berelatively thinner (e.g., T₁<0.075 inch) without degrading thestructural integrity, sound, and/or feel of the golf club head 100. Inone example, the first thickness 1510 may be less than or equal to 0.060inch (1.524 millimeters) (e.g., T₁≤0.060 inch). In another example, thefirst thickness 1510 may be less than or equal to 0.040 inch (1.016millimeters) (e.g., T₁≤0.040 inch). Based on the type of material(s)used to form the face portion 162 and/or the body portion 110, the faceportion 162 may be even thinner with the first thickness 1510 being lessthan or equal to 0.030 inch (0.762 millimeters) (e.g., T₁≤0.030 inch).The groove depth 1525 may be greater than or equal to the secondthickness 1520 (e.g., D_(groove)≥T₂). In one example, the groove depth1525 may be about 0.020 inch (0.508 millimeters) (e.g., D_(groove)=0.020inch). Accordingly, the second thickness 1520 may be about 0.010 inch(0.254 millimeters) (e.g., T₂=0.010 inch). In another example, thegroove depth 1525 may be about 0.015 inch (0.381 millimeters), and thesecond thickness 1520 may be about 0.015 inch (e.g., D_(groove)=T₂=0.015inch). Alternatively, the groove depth 1525 may be less than the secondthickness 1520 (e.g., D_(groove)<T₂). Without the support of the backwall portion 1410 and the elastic polymer material to fill in theinterior cavity 700, a golf club head may not be able to withstandmultiple impacts by a golf ball on a face portion. In contrast to thegolf club head 100 as described herein, a golf club head with arelatively thin face portion but without the support of the back wallportion 1410 and the elastic polymer material to fill in the interiorcavity 700 (e.g., a cavity-back golf club head) may produce unpleasantsound (e.g., a tinny sound) and/or feel during impact with a golf ball.The apparatus, methods, and articles of manufacture described herein arenot limited in this regard.

Based on manufacturing processes and methods used to form the golf clubhead 100, the face portion 162 may include additional material at orproximate to a periphery of the face portion 162. Accordingly, the faceportion 162 may also include a third thickness 1530, and a chamferportion 1540. The third thickness 1530 may be greater than either thefirst thickness 1510 or the second thickness 1520 (e.g., T₃>T₁>T₂). Inparticular, the face portion 162 may be coupled to the body portion 110by a welding process. For example, the first thickness 1510 may be about0.030 inch (0.762 millimeters), the second thickness 1520 may be about0.015 inch (0.381 millimeters), and the third thickness 1530 may beabout 0.050 inch (1.27 millimeters). Accordingly, the chamfer portion1540 may accommodate some of the additional material when the faceportion 162 is welded to the body portion 110.

As illustrated in FIG. 16, for example, the face portion 162 may includea reinforcement section, generally shown as 1605, below one or moregrooves 168. In one example, the face portion 162 may include areinforcement section 1605 below each groove. Alternatively, faceportion 162 may include the reinforcement section 1605 below somegrooves (e.g., every other groove) or below only one groove. The faceportion 162 may include a first thickness 1610, a second thickness 1620,a third thickness 1630, and a chamfer portion 1640. The groove 168 mayhave a groove depth 1625. The reinforcement section 1605 may define thesecond thickness 1620. The first and second thicknesses 1610 and 1620,respectively, may be substantially equal to each other (e.g., T₁=T₂). Inone example, the first and second thicknesses 1610 and 1620,respectively, may be about 0.030 inch (0.762 millimeters) (e.g.,T₁=T₂=0.030 inch). The groove depth 1625 may be about 0.015 inch (0.381millimeters), and the third thickness 1630 may be about 0.050 inch (1.27millimeters). The groove 168 may also have a groove width. The width ofthe reinforcement section 1605 may be greater than or equal to thegroove width. The apparatus, methods, and articles of manufacturedescribed herein are not limited in this regard.

Alternatively, the face portion 162 may vary in thickness at and/orbetween the top portion 180 and the sole portion 190. In one example,the face portion 162 may be relatively thicker at or proximate to thetop portion 180 than at or proximate to the sole portion 190 (e.g.,thickness of the face portion 162 may taper from the top portion 180towards the sole portion 190). In another example, the face portion 162may be relatively thicker at or proximate to the sole portion 190 thanat or proximate to the top portion 180 (e.g., thickness of the faceportion 162 may taper from the sole portion 190 towards the top portion180). In yet another example, the face portion 162 may be relativelythicker between the top portion 180 and the sole portion 190 than at orproximate to the top portion 180 and the sole portion 190 (e.g.,thickness of the face portion 162 may have a bell-shaped contour). Theapparatus, methods, and articles of manufacture described herein are notlimited in this regard.

Different from other golf club head designs, the interior cavity 700 ofthe body portion 110 and the location of the first and second sets ofweight portions 120 and 130, respectively, along the perimeter of thegolf club head 100 may result in a golf ball traveling away from theface portion 162 at a relatively higher ball launch angle and arelatively lower spin rate. As a result, the golf ball may travelfarther (i.e., greater total distance, which includes carry and rolldistances).

FIG. 17 depicts one manner in which the example golf club head describedherein may be manufactured. In the example of FIG. 17, the process 1700may begin with providing two or more weight portions, generally shown asthe first and second sets of weight portions 120 and 130, respectively(block 1710). The first and second sets of weight portions 120 and 130,respectively, may be made of a first material such as a tungsten-basedmaterial. In one example, the weight portions of the first and secondsets 120 and 130, respectively, may be tungsten-alloy screws.

The process 1700 may provide a body portion 110 having the face portion162, the interior cavity 700, and the back portion 170 with two or moreexterior weight ports, generally shown as 1420 and 1430 (block 1720).The body portion 110 may be made of a second material, which isdifferent than the first material. The body portion 110 may bemanufacture using an investment casting process, a billet forgingprocess, a stamping process, a computer numerically controlled (CNC)machining process, a die casting process, any combination thereof, orother suitable manufacturing processes. In one example, the body portion110 may be made of 17-4 PH stainless steel using a casting process. Inanother example, the body portion 110 may be made of other suitable typeof stainless steel (e.g., Nitronic® 50 stainless steel manufactured byAK Steel Corporation, West Chester, Ohio) using a forging process. Byusing Nitronic® 50 stainless steel to manufacture the body portion 110,the golf club head 100 may be relatively stronger and/or more resistantto corrosion than golf club heads made from other types of steel. Eachweight port of the body portion 110 may include an opening and a portwall. For example, the weight port 1421 may include the opening 720 andthe port wall 725 with the opening 720 and the port wall 725 being onopposite ends of each other. The interior cavity 700 may separate theport wall 725 of the weight port 1421 and the back surface 166 of theface portion 162. In a similar manner, the weight port 1835 may includethe opening 730 and the port wall 735 with the opening 730 and the portwall 735 being on opposite ends of each other. The interior cavity 700may separate the port wall 735 of the weight port 1435 and the backsurface 166 of the face portion 162.

The process 1700 may couple each of the first and second sets of weightportions 120 and 130 into one of the two or more exterior weight ports(blocks 1730). In one example, the process 1700 may insert and securethe weight portion 121 in the exterior weight port 1421, and the weightportion 135 in the exterior weight portion 1435. The process 1700 mayuse various manufacturing methods and/or processes to secure the firstand second sets of weight portions 120 and 130, respectively, in theexterior weigh ports such as the weight ports 1421 and 1435 (e.g.,epoxy, welding, brazing, mechanical lock(s), any combination thereof,etc.).

The process 1700 may partially or entirely fill the interior cavity 700with an elastic polymer material (e.g., Sorbothane® material) (block1740). In one example, at least 50% of the interior cavity 700 may befilled with the elastic polymer material. As mentioned above, theelastic polymer material may absorb shock, isolate vibration, and/ordampen noise in response to the golf club head 100 striking a golf ball.In addition or alternatively, the interior cavity 700 may be filled witha thermoplastic elastomer material and/or a thermoplastic polyurethanematerial. As illustrated in FIG. 18, for example, the golf club head 100may include one or more weight ports (e.g., one shown as 1431 in FIG.14) with a first opening 1830 and a second opening 1835. The secondopening 1835 may be used to access the interior cavity 700. In oneexample, the process 1700 (FIG. 17) may fill the interior cavity 700with an elastic polymer material by injecting the elastic polymermaterial into the interior cavity 700 from the first opening 1830 viathe second opening 1835 (for example, as shown in FIG. 19, the polymermaterial may be injected into the interior cavity 700 from one of theports at block 1940 of the process 1900 for manufacturing a golf club).The first and second openings 1830 and 1835, respectively, may be sameor different in size and/or shape. While the above example may describeand depict a particular weight port with a second opening, any otherweight ports of the golf club head 100 may include a second opening(e.g., the weight port 720). The apparatus, methods, and articles ofmanufacture described herein are not limited in this regard.

Referring back to FIG. 17, the example process 1700 is merely providedand described in conjunction with other figures as an example of one wayto manufacture the golf club head 100. While a particular order ofactions is illustrated in FIG. 17, these actions may be performed inother temporal sequences. For example, two or more actions depicted inFIG. 17 may be performed sequentially, concurrently, or simultaneously.In one example, blocks 1710, 1720, 1730, and/or 1740 may be performedsimultaneously or concurrently. Although FIG. 17 depicts a particularnumber of blocks, the process may not perform one or more blocks. In oneexample, the interior cavity 700 may not be filled (i.e., block 1740 maynot be performed). The apparatus, methods, and articles of manufacturedescribed herein are not limited in this regard.

The apparatus, methods, and articles of manufacture described herein maybe implemented in a variety of embodiments, and the foregoingdescription of some of these embodiments does not necessarily representa complete description of all possible embodiments. Instead, thedescription of the drawings, and the drawings themselves, disclose atleast one embodiment, and may disclosure alternative embodiments.

As the rules of golf may change from time to time (e.g., new regulationsmay be adopted or old rules may be eliminated or modified by golfstandard organizations and/or governing bodies such as the United StatesGolf Association (USGA), the Royal and Ancient Golf Club of St. Andrews(R&A), etc.), golf equipment related to the apparatus, methods, andarticles of manufacture described herein may be conforming ornon-conforming to the rules of golf at any particular time. Accordingly,golf equipment related to the apparatus, methods, and articles ofmanufacture described herein may be advertised, offered for sale, and/orsold as conforming or non-conforming golf equipment. The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

Although certain example apparatus, methods, and articles of manufacturehave been described herein, the scope of coverage of this disclosure isnot limited thereto. On the contrary, this disclosure covers allapparatus, methods, and articles of articles of manufacture fairlyfalling within the scope of the appended claims either literally orunder the doctrine of equivalents.

What is claimed is:
 1. A method of manufacturing a golf club head, themethod comprising: forming a body portion having a toe portion, a heelportion, a top portion, a sole portion, an interior cavity portion, aback portion, a first plurality of weight ports located in the backportion between a horizontal midplane and a top plane, and a secondplurality of weight ports located in the back portion between thehorizontal midplane and a ground plane; forming a face portioncomprising a strike face having a groove and a reinforcement sectionadjacent to the groove; attaching the face portion to the body portionto close the interior cavity portion; injecting a polymer material intothe interior cavity portion through one of the second plurality ofweight ports, wherein the polymer material fills at least a portion ofthe interior cavity portion and extends from the back portion to theface portion; providing a first plurality of weight portions andinserting each of the first plurality of weight portions into a weightport of the first plurality of weight ports; and providing a secondplurality of weight portions and inserting each of the second pluralityof weight portions into a weight port of the second plurality of weightports.
 2. A method as defined in claim 1, wherein a greater number ofthe second plurality of weight ports are located closer to the toeportion than to the heel portion.
 3. A method as defined in claim 1,wherein each weight port of the second plurality of weight ports has aport diameter, and wherein each exterior port of the second plurality ofweight ports is separated from an adjacent weight port by a distance ofless than or equal to the port diameter.
 4. A method as defined in claim1, wherein the second plurality of weight ports are arranged in a rowalong a bottom periphery of the back portion.
 5. A method as defined inclaim 1, wherein forming the face portion comprises forming the faceportion having a thickness of less than or equal to 1.905 millimeters(0.075 inch).
 6. A method as defined in claim 1, wherein forming theface portion comprises forming the face portion having a thickness ofless than or equal to 1.016 millimeters (0.040 inch).
 7. A method asdefined in claim 1, wherein forming the face portion comprises formingthe face portion having a thickness of less than or equal to 0.762millimeters (0.030 inch).
 8. A method of manufacturing a golf club head,the method comprising: forming a body portion having a toe portion, aheel portion, a top portion, a sole portion, an interior cavity portion,a back portion, and a plurality of exterior ports, the plurality ofexterior ports comprising a first set of exterior ports formed in theback portion above a horizontal midplane and closer to the toe portionthan the heel portion, and a second set of exterior ports formed in theback portion below the horizontal midplane and extending from the toeportion to the heel portion; forming a face portion having a thicknessof less than or equal to 1.524 millimeters (0.060 inch); coupling theface portion to the body portion to close the interior cavity portion;injecting a shock-absorbing elastic polymer material into the interiorcavity portion through one of the plurality of exterior ports; providinga first set of mass portions and coupling each of the first set of massportions to a corresponding exterior port of the first set of exteriorports; and providing a second set of mass portions and coupling each ofthe second set of mass portions to a corresponding exterior port of thesecond set of exterior ports.
 9. A method as defined in claim 8, whereinthe shock-absorbing elastic polymer material extends from the backportion to the face portion within the interior cavity portion.
 10. Amethod as defined in claim 8, wherein the body portion comprises a firstmaterial and the second set of mass portions comprise a second material,the first material being a metal material and the second material beinga non-metal material.
 11. A method as defined in claim 8, wherein thebody portion comprises a first material and the second set of massportions comprise a second material, the second material having adensity greater than the first material.
 12. A method as defined inclaim 8, wherein attaching the face portion to the body portioncomprises welding or brazing the face portion to the body portion.
 13. Amethod as defined in claim 8, wherein each of the first set of massportions is associated with a first height and each of the second set ofmass portions is associated with a second height, and wherein the firstheight is shorter than the second height.
 14. A method as defined inclaim 8, wherein each of the first set of mass portions is associatedwith a first height of less than or equal to 3.175 millimeters (0.125inch) and each of the second set of mass portions is associated with asecond height of less than or equal to 7.62 millimeters (0.3 inch). 15.A method of manufacturing a golf club, the method comprising: forming abody portion having a toe portion, a heel portion, a top portion, a soleportion, an interior cavity portion, a back portion, a first pluralityof threaded openings located in the back portion above a horizontalmidplane, and a second plurality of threaded openings located in theback portion below the horizontal midplane; forming a face portioncomprising a strike face having a plurality of grooves and areinforcement section between each pair of adjacent grooves; joining theface portion to the body portion to close the interior cavity portion;injecting a polymer material into the interior cavity portion throughone of the first plurality of threaded openings or one of the secondplurality of threaded openings, wherein the polymer materialsubstantially fills the interior cavity portion and extends from theback portion to the face portion, wherein the polymer material isconfigured to dampen vibrations resulting from the face portion strikinga golf ball; providing a first plurality of threaded plugs and closingeach of the first plurality of threaded openings with one of the firstplurality of threaded plugs; providing a second plurality of threadedplugs and closing each of the second plurality of threaded openings withone of the second plurality of threaded plugs; and attaching a shaft tothe body portion.
 16. A method as defined in claim 15, wherein a mass ofthe second plurality of threaded plugs is greater than a mass of thefirst plurality of threaded plugs.
 17. A method as defined in claim 15,wherein the second plurality of threaded plugs have a mass that is morethan 50% of a collective mass of the first plurality of threaded plugsand the second plurality of threaded plugs.
 18. A method as defined inclaim 15, wherein the first plurality of threaded plugs and the secondplurality of threaded plugs do not extend into the interior cavityportion.
 19. A method as defined in claim 15, wherein the firstplurality of threaded openings are located in the toe portion andarranged in a row along a top periphery of the back portion.
 20. Amethod as defined in claim 15, wherein the second plurality of threadedopenings are arranged in a row along a bottom periphery of the backportion and extend from the toe portion to the heel portion.